Chrysler PT Cruiser. Manual - part 3

TABLE OF CONTENTS - Continued

HEADLAMP RELAY (RHD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405
HANDS FREE MODULE C1 - DK. GRAY 22 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .406
HANDS FREE MODULE C2 (SATELLITE RADIO) - DK. GRAY 10 WAY . . . . . . . . . .406
HANDS FREE MODULE C3 - BLACK 10 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406
HIGH NOTE HORN (EXPORT) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .407
HOOD AJAR SWITCH (EXPORT) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . .407
IGNITION SWITCH C1 - 10 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .407
INSTRUMENT CLUSTER C1 - BLACK 26 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408
INSTRUMENT CLUSTER C2 - BLACK 10 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408
LEFT CYLINDER LOCK SWITCH - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . .409
LEFT DOOR LOCK SWITCH - BLACK 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409
LEFT FRONT POWER WINDOW MOTOR (PT44) - BLACK 2 WAY . . . . . . . . . . . . . .409
LEFT INSTRUMENT PANEL SPEAKER - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . .409
LEFT REAR SPEAKER (PT44) - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410
LEFT SEAT AIRBAG SQUIB (LHD) - YELLOW 2 WAY . . . . . . . . . . . . . . . . . . . . . . . .410
LEFT SEAT AIRBAG SQUIB (RHD) - YELLOW 2 WAY . . . . . . . . . . . . . . . . . . . . . . . .410
LEFT SIDE IMPACT SENSOR 1 - GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410
LIFTGATE AJAR SWITCH - WHITE 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .411
LIFTGATE CYLINDER LOCK SWITCH - LT. GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . .411
LIFTGATE HANDLE SWITCH (PT44) - NATURAL 2 WAY . . . . . . . . . . . . . . . . . . . . . .411
LIFTGATE POWER LOCK MOTOR - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . .411
LIFTGATE RELEASE MOTOR (PT44) - BLACK 3 WAY. . . . . . . . . . . . . . . . . . . . . . . .412
LOW NOTE HORN - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412
MULTI-FUNCTION SWITCH - GRAY 20 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412
OVERHEAD CONSOLE MODULE - BLACK 12 WAY. . . . . . . . . . . . . . . . . . . . . . . . . .413
PASSENGER AIRBAG SQUIB 1 - YELLOW 2 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . .413
PASSENGER DOOR AJAR SWITCH - BLACK 2 WAY . . . . . . . . . . . . . . . . . . . . . . . .413
PASSENGER DOOR HANDLE SWITCH (PT27) - 2 WAY . . . . . . . . . . . . . . . . . . . . . .414
PASSENGER DOOR POWER LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY . . . .414
PASSENGER REAR WINDOW MOTOR (PT27) - BLACK 2 WAY. . . . . . . . . . . . . . . .414
PASSENGER SEAT BELT TENSIONER - YELLOW 2 WAY . . . . . . . . . . . . . . . . . . . .414
PASSENGER WINDOW REGULATOR MODULE (PT27) - BLACK 20 WAY . . . . . . .415
FUSES (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .417
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .417
POWER TOP MOTOR (PT27) - 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .418
POWER TOP RELAY (PT27) - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .418
POWER TOP SWITCH (PT27) - 3 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .418
POWERTRAIN CONTROL MODULE (1.6L) - BLACK 90 WAY . . . . . . . . . . . . . . . . . .419
POWERTRAIN CONTROL MODULE C1 (NGC) - BLACK/BLACK 38 WAY . . . . . . . .420
RADIO C1 - WHITE 22 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421
RADIO C2 (HANDS FREE) - DK. GRAY 10 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421
REAR VIEW MIRROR C1 - BLACK 12 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .422
REMOTE KEYLESS ENTRY MODULE - BLACK 26 WAY . . . . . . . . . . . . . . . . . . . . . .422
RIGHT CYLINDER LOCK SWITCH (EXPORT) - BLACK 2 WAY. . . . . . . . . . . . . . . . .423
RIGHT DOOR LOCK SWITCH - BLACK 3 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .423
RIGHT FRONT DOOR SPEAKER - 3 WAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .423
RIGHT FRONT POWER WINDOW MOTOR (PT44) - BLACK 2 WAY. . . . . . . . . . . . .423
RIGHT REAR POWER WINDOW MOTOR (PT44) - BLACK 2 WAY . . . . . . . . . . . . . .424
RIGHT SEAT AIRBAG SQUIB (LHD) - YELLOW 2 WAY . . . . . . . . . . . . . . . . . . . . . . .424
RIGHT SEAT AIRBAG SQUIB (RHD) - YELLOW 2 WAY . . . . . . . . . . . . . . . . . . . . . . .424
RIGHT SIDE IMPACT SENSOR 1 - GRAY 2 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .425
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY . . . . . . . . . . . . . . . . . . . . . .425
SIREN (EXPORT) - BLACK 4 WAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .425

TABLE OF CONTENTS - Continued

10.0

SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .427

10.1 AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .427

10.1.1

BASE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .427

10.1.2

PREMIUM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .428

10.2 AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .429

10.2.1

SATELLITE DIGITAL AUDIO RECEIVER SYSTEM (SDARS) . . . . . .430

10.2.2

SATELLITE DIGITAL AUDIO RECEIVER SYSTEM (SDARS)
EQUIPPED WITH HANDS FREE MODULE (HFM) . . . . . . . . . . . . . .431

10.3 COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .432
10.4 COMPASS/TEMPERATURE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433

10.4.1

COMPASS/TEMPERATURE MIRROR MODULE (PT27) . . . . . . . . . .433

10.5 INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .434
10.6 INTERIOR LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .435
10.7 POWER DOOR LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436

10.7.1

PT44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436

10.7.2

PT27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .437

10.8 POWER TOP (PT27). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438
10.9 POWER WINDOWS (PT27) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .439
10.10 TELECOMMUNICATIONS – HANDS FREE MODULE (HFM) . . . . . . . . . . . . . .440
10.11 VEHICLE THEFT SECURITY SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441

1.0

INTRODUCTION

The procedures contained in this manual include

all the specifications, instructions, and graphics
needed to diagnose body system problems. The
diagnostics in this manual are based on the failure
condition or symptom being present at time of
diagnosis.

Please follow the recommendations below when

choosing your diagnostic path.

1. First make sure the DRBIII

t is communicating

with the appropriate modules; i.e., if the
DRBIII

t displays a “No Response” or “Bus +/-

signal open” condition, you must diagnose that
first.

2. Read DTC’s (diagnostic trouble codes) with the

DRBIII

3. If no DTC’s are present, identify the customer

complaint.

4. Once the DTC or customer complaint is identi-

fied, locate the matching test in the Table of
Contents and begin to diagnose the symptom.

All component location views are in Section 8.0.

All connector pinouts are in Section 9.0. All sche-
matics are in Section 10.0.

An * placed before the symptom description indi-

cates a customer complaint.

When repairs are required, refer to the appropri-

ate service manual for the proper removal and
repair procedure.

Diagnostic procedures change every year. New

diagnostic systems may be added; carryover sys-
tems may be enhanced. READ THIS MANUAL
BEFORE TRYING TO DIAGNOSE A VEHICLE
DIAGNOSTIC TROUBLE CODE. It is recom-
mended that you review the entire manual to be-
come familiar with all new and changed diagnostic
procedures.

This book reflects many suggested changes from

readers of past issues. After using this book, if you
have any comments or suggestions, please fill out the
form in the back of this book and mail it back to us.

1.1

SYSTEM COVERAGE

This diagnostic procedures manual covers all

2005 PT27 and PT44 CRUISER VEHICLES.

1.2

SIX-STEP TROUBLESHOOTING
PROCEDURE

Diagnosis of the body system is done in six basic

steps:

•

verification of complaint

•

verification of any related symptoms

•

symptom analysis

•

problem isolation

•

repair of isolated problem

•

verification of proper operation

2.0

IDENTIFICATION OF
SYSTEM

The vehicle systems that are part of the “body”

system are:

•

Airbag

•

Audio

•

Communication

•

Instrument Cluster

•

Power Convertible Top

•

Power Door Lock/RKE

•

Power Windows (PT27)

•

Telecommunications - Hands Free Phone

•

Vehicle theft security system (VTSS)

3.0

SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION

The body system on the PT consists of a combi-

nation of modules that communicate over the PCI
bus (Programmable Communication Interface mul-
tiplex system). Through the PCI bus, information
about the operation of vehicle components and
circuits is relayed quickly to the appropriate mod-
ule(s). All modules receive all the information trans-
mitted on the bus even though a module may not
require all information to perform it’s function. It
will only respond to messages “addressed” to it
through a binary coding process. This method of
data transmission significantly reduces the com-
plexity of the wiring in the vehicle and the size of
wiring harnesses. All of the information about the
functioning of all the systems is organized, con-
trolled, and communicated by the PCI bus, which is
described in the Vehicle Communication Section of
this general information.

3.1

AIRBAG SYSTEM

The Airbag system is equipped with two types of

Occupant Restraint Controller or ORC, base and
premium. The ORC is a specific type of Airbag
Control Module or ACM. The term Airbag Control
Module or ACM will be used throughout the airbag
diagnostic book and the Diagnostic Readout Box or
DRB III

t. The DRB IIIt is a scan tool use to

interrogate the ACM to retrieve Diagnostic Trouble
Codes or DTC

8s and other system information.

The ACM is secured to a bracket on the floor

panel transmission tunnel between the floor shifter

GENERAL INFORMATION

and parking brake. The ACM contains a micropro-
cessor, impact sensor, and energy storage capaci-
tors. The microprocessor contains the airbag system
logic. The airbag system logic includes On-Board
Diagnostics OBD capability, and communicates
with the instrument cluster circuitry on the Pro-
grammable Communication Interface (PCI) data
bus to control the airbag warning indicator. The
microprocessor in the ACM monitors the internal
and external circuits to determine the system readi-
ness. If the ACM detects a monitored system fault,
it sends messages to the Mechanical Instrument
Cluster (MIC) over the PCI data bus to turn on the
Airbag Warning Indicator and provides the electri-
cal signal to deploy the airbag system components.
The impact sensor is an accelerometer that senses
the rate of vehicle deceleration, which provides
verification of the direction and severity of an
impact. The impact sensor is calibrated for the
specific vehicle, and is only serviced as a unit with
the ACM. The ACM also contains an energy-storage
capacitor. This capacitor stores enough electrical
energy to deploy the airbags if the initial impact has
damaged or disconnected the battery, but not severe
enough to deploy the airbags. The ACM cannot be
repaired or adjusted and, if damaged or faulty, it
must be replaced.

The Base ACM can be identified by the present of

a single yellow 23 - way connector. This module
supports the Driver and Passenger Seat Belt Ten-
sioners and dual squib airbags.

The Premium ACM can be identified by the

present of a two yellow 32 - way connectors and the
presents of seat airbag. In addition to the base
system components and DTC’s the premium ACM
supports the Side Impact Sensors, Side Seat Airbags
to provide verification of the direction and severity of
an impact from the front and both sides. In addition
to the base ACM DTCs the premium ACM provides
DTC’s for the additional circuit and component.

WARNING:

THE

AIRBAG

SYSTEM

SENSITIVE, COMPLEX ELECTROMECHANICAL
UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR
SERVICE ANY AIRBAG SYSTEM OR RELATED
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT

PANEL

COMPONENTS

YOU

MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE. WAIT
TWO MINUTES FOR THE SYSTEM CAPACITOR
TO DISCHARGE BEFORE FURTHER SYSTEM
SERVICE. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIRBAG SYSTEM. FAILURE TO
DO THIS COULD RESULT IN ACCIDENTAL
AIRBAG

DEPLOYMENT

AND

POSSIBLE

PERSONAL INJURY. NEVER STRIKE OR KICK

THE AIRBAG CONTROL MODULE, AS IT CAN
DAMAGE THE IMPACT SENSOR OR AFFECT
ITS

CALIBRATION.

OCCUPANT

RESTRAINT CONTROLLER IS ACCIDENTALLY
DROPPED DURING SERVICE, THE MODULE
MUST BE SCRAPPED AND REPLACED WITH A
NEW UNIT. FAILURE TO TAKE THE PROPER
PRECAUTIONS

COULD

RESULT

ACCIDENTAL

AIRBAG

DEPLOYMENT

AND

PERSONAL INJURY OR DEATH.

The Airbag Warning Indicator is the only point at

which the customer can observe ‘‘symptoms’’ of a
system malfunction. Whenever the ignition key is
turned to the ‘‘run’’ or ‘‘start’’ position, the ACM
performs a lamp check by turning the AIRBAG
warning lamp on for 6 to 8 seconds. If the lamp
remains off, it means that the ORC has checked the
system and found it to be free of discernible mal-
functions. If the indicator remains on, there could
be an active fault in the ACM system.

3.1.1

DRIVER AIRBAG MODULE (DAB)

The airbag protective trim cover is the most

visible part of the driver side airbag system. The
module is mounted directly to the steering wheel.
Located under the trim cover are the horn switch,
the airbag cushion, and the airbag cushion support-
ing components. The airbag module includes a
housing to which the cushion and inflator are
attached and sealed. The airbag module cannot be
repaired, and must be replaced if deployed or in any
way damaged. The inflator assembly is mounted to
the back of the airbag module. The inflator seals the
hole in the airbag cushion so it can discharge the
gas it produces directly into the cushion when
supplied with the proper electrical signal. The pro-
tective trim cover is fitted to the front of the airbag
module and forms a decorative cover in the center of
the steering wheel. Upon airbag deployment, this
cover will split at a predetermined breakout line.

WARNING: TO AVOID PERSONAL INJURY OR
DEATH, THE AIRBAG MODULE INFLATOR
ASSEMBLY CONTAINS SODIUM AZIDE AND
POTASSIUM NITRATE. THESE MATERIALS
ARE

POISONOUS

AND

EXTREMELY

FLAMMABLE. CONTACT WITH ACID, WATER,
OR

HEAVY

METALS

MAY

PRODUCE

HARMFUL AND IRRITATING GASES (SODIUM
HYDROXIDE IS FORMED IN THE PRESENCE
OF

MOISTURE)

COMBUSTIBLE

COMPOUNDS.

NOT

PUNCTURE,

INCINERATE, OR BRING INTO CONTACT
WITH ELECTRICITY. DO NOT STORE AT
TEMPERATURE EXCEEDING 93°C (200°F).

GENERAL INFORMATION

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